Blade grinding systems and methods

ABSTRACT

A method of grinding a plurality of tufting blades of a blade assembly is disclosed. The plurality of tufting blades can be received within a blade block during grinding. The blade assembly can have a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes. Each tufting blade of the plurality of tufting blades can have a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis. The plurality of tufting blades can be spaced from each other along the third axis. The blade block can include at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims priority to and the benefit of the filing dateof U.S. Provisional Pat. Application No. 63/293,254, filed Dec. 23,2021, which is incorporated herein by reference in its entirety.

FIELD

This disclosure is directed to blades for tufting apparatuses and, inparticular, to grinding said blades when held within a blade block.

BACKGROUND

Tufting apparatuses have a plurality of tufting blades that are heldwithin a blade block. The tufting blades are configured to cut yarns oftufted articles. The tufting blades must be sharpened periodically.Conventionally, the tufting blades are removed from the blade block, andthe tufting blades are then sharpened individually. This process isslow, costly, labor intensive, and subject to human error. Accordingly,an automated process that reduces one or more of operator interaction,time, or human error is desirable.

SUMMARY

Disclosed herein is a method of grinding a plurality of tufting bladesof a blade assembly. The plurality of tufting blades can be receivedwithin a blade block during grinding. The blade assembly can have afirst axis, a second axis that is parallel to the first axis, and athird axis that is perpendicular to each of the first and second axes.Each tufting blade of the plurality of tufting blades can have a lengththat extends along the first axis, a width that extends along the secondaxis, and a thickness that extends along the third axis. The pluralityof tufting blades can be spaced from each other along the third axis.The blade assembly can comprise at least one fastener that is configuredto retain the plurality of tufting blades in respective fixed positionsrelative to the blade block.

Also disclosed herein is a system for grinding blade assemblies. Thesystem can comprise a blade assembly. The blade assembly can comprise aplurality of tufting blades received within a blade block. The bladeassembly can have a first axis, a second axis that is parallel to thefirst axis, and a third axis that is perpendicular to each of the firstand second axes. Each tufting blade of the plurality of tufting bladescan have a length that extends along the first axis, a width thatextends along the second axis, and a thickness that extends along thethird axis. The plurality of tufting blades can be spaced from eachother along the third axis. The blade assembly can comprise at least onefastener that is configured to retain the plurality of tufting blades inrespective fixed positions relative to the blade block. The system canfurther comprise a fixture that is configured to hold the blade assemblyand a grinder that is configured to grind the tufting blades of theblade assembly held within the fixture.

Additional advantages of the disclosed system and method will be setforth in part in the description which follows, and in part will beunderstood from the description, or may be learned by practice of thedisclosed system and method. The advantages of the disclosed system andmethod will be realized and attained by means of the elements andcombinations particularly pointed out in the appended claims. It is tobe understood that both the foregoing general description and thefollowing detailed description are exemplary and explanatory only andare not restrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a blade assembly comprising a pluralityof tufting blades held within a blade block in a use configuration.

FIG. 2 is a perspective view of a plurality of blade assemblies as inFIG. 1 held within a fixture for grinding.

FIG. 3A is a schematic diagram of a blade block and grinding wheellooking along a grinding wheel movement axis, illustrating the formationof the blade angle. FIG. 3B is a schematic diagram of the blade blockand grinding wheel looking perpendicular to the grinding wheel movementaxis, showing the formation of a relief angle.

FIG. 4 is a perspective view of a first blade alignment assembly forpositioning the tufting blades relative to the blade block.

FIG. 5 is a perspective view of a blade assembly comprising a pluralityof tufting blades held within a blade block in a grinding configuration.

FIG. 6 is a bird’s eye view of a system for grinding blade assemblies asdisclosed herein.

FIG. 7 is a perspective view of tray holding a plurality of a bladeassemblies as in FIG. 1 .

FIG. 8 is a rear perspective view of the system as in FIG. 6 .

FIG. 9 is a front perspective view of the system as in FIG. 6 .

FIG. 10A is a first perspective view of a second end of arm tool of thesystem of FIG. 6 , depicting the tool loading blade assemblies into afixture. FIG. 10B is a perspective view of the second end of arm toolwhile gripping a pair of fixtures holding blade assemblies. FIG. 10C isa perspective view of the second end of arm tool while moving along arail toward a grinder. FIG. 10D is a perspective view of the second endof arm tool while holding a pair of fixtures holding un-ground bladeassemblies and positioning itself for gripping a pair of fixturesholding ground blade assemblies. FIG. 10E is a perspective view of thesecond end of arm tool while rotating to position the fixtures holdingun-ground blade assemblies for placement in the grinder. FIG. 10F is aperspective view of the second end of arm tool while placing thefixtures holding un-ground blade assemblies in the grinder. FIG. 10Gshows a detail perspective view of the second end of arm tool placingblade assemblies in a fixture.

FIG. 11 is a perspective view of a second blade alignment assembly forpositioning the tufting blades relative to the blade block.

FIG. 12 is another perspective view of the first blade alignmentassembly of FIG. 4 for positioning the tufting blades relative to theblade block.

FIG. 13A is a perspective view of the first end of arm tool and aportion of the system of FIG. 6 . FIG. 13B is another perspective viewof the first end of arm tool and a portion of the system of FIG. 6 .FIG. 13C shows a detail perspective view of the first end of arm tool.FIG. 13D shows a perspective view of a cleaning station. FIG. 13E showsa perspective view of a deburring station. FIG. 13F shows a partialperspective view of the system including post-grinding stations such asa cleaning station, a printing station, a visual inspection station, anda third robotic arm for handling ground blade assemblies. FIG. 13F showsthe first end of arm tool separate from the first robotic arm in aplurality of different positions at the visual inspection station.

FIG. 14 is a schematic diagram of a system network for communicatingbetween various components of the system of FIG. 6 .

FIG. 15 is a block diagram of control system comprising a computingdevice as disclosed herein.

DETAILED DESCRIPTION

The disclosed articles, systems and methods may be understood morereadily by reference to the following detailed description of particularembodiments and the examples included therein and to the Figures andtheir previous and following description.

It is to be understood that the terminology used herein is for thepurpose of describing particular embodiments only and is not intended tolimit the scope of the present disclosure which will be limited only bythe appended claims.

It must be noted that as used herein and in the appended claims, thesingular forms “a,” “an,” and “the” include plural references unless thecontext clearly dictates otherwise. Thus, for example, reference to “ablade block” includes one or more of such blade blocks, and so forth.

“Optional” or “optionally” means that the subsequently described event,circumstance, or material may or may not occur or be present, and thatthe description includes instances where the event, circumstance, ormaterial occurs or is present and instances where it does not occur oris not present.

Ranges may be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, also specifically contemplated and considered disclosed isthe range from the one particular value and/or to the other particularvalue unless the context specifically indicates otherwise. Similarly,when values are expressed as approximations, by use of the antecedent“about,” it will be understood that the particular value forms another,specifically contemplated embodiment that should be considered disclosedunless the context specifically indicates otherwise. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint unless the context specifically indicates otherwise. Finally,it should be understood that all of the individual values and sub-rangesof values contained within an explicitly disclosed range are alsospecifically contemplated and should be considered disclosed unless thecontext specifically indicates otherwise. The foregoing appliesregardless of whether in particular cases some or all of theseembodiments are explicitly disclosed.

Optionally, in some aspects, when values are approximated by use of theantecedents “about,” “substantially,” or “generally,” it is contemplatedthat values within up to 15%, up to 10%, up to 5%, or up to 1% (above orbelow) of the particularly stated value or characteristic can beincluded within the scope of those aspects.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meanings as commonly understood by one of skill in the artto which the disclosed apparatus, system, and method belong. Althoughany apparatus, systems, and methods and materials similar or equivalentto those described herein can be used in the practice or testing of thepresent apparatus, system, and method, the particularly useful methods,devices, systems, and materials are as described.

Throughout the description and claims of this specification, the word“comprise” and variations of the word, such as “comprising” and“comprises,” means “including but not limited to,” and is not intendedto exclude, for example, other additives, components, integers or steps.In particular, in methods stated as comprising one or more steps oroperations it is specifically contemplated that each step comprises whatis listed (unless that step includes a limiting term such as “consistingof”), meaning that each step is not intended to exclude, for example,other additives, components, integers or steps that are not listed inthe step.

It is to be understood that unless otherwise expressly stated, it is inno way intended that any method set forth herein be construed asrequiring that its steps be performed in a specific order. Accordingly,where a method claim does not actually recite an order to be followed byits steps or it is not otherwise specifically stated in the claims ordescriptions that the steps are to be limited to a specific order, it isin no way intended that an order be inferred, in any respect. This holdsfor any possible non-express basis for interpretation, including:matters of logic with respect to arrangement of steps or operationalflow; plain meaning derived from grammatical organization orpunctuation; and the number or type of aspects described in thespecification. Thus, words denoting order, such as “first” or “next,”should be interpreted as optional aspects unless plain meaning or logicdictates otherwise.

Disclosed herein and with reference to FIGS. 6, 8, and 9 is a system 100for grinding tufting blades of blade assemblies. Referring to FIGS. 1-5, a blade assembly 10 can comprise a blade block 12 and a plurality oftufting blades 14 (or “blades” as used interchangeably herein) receivedwithin the blade block. The blade assembly 10 can have a first axis 16,a second axis 18 that is parallel to the first axis, and a third axis 20that is perpendicular to each of the first and second axes. The tuftingblades 14 can be spaced along the third axis 20 relative to each other.Each of the tufting blades 14 can define a blade edge 22 at a firstlongitudinal end 24. The blade assembly 10 can comprise one or morefasteners 26 that are configured to retain the plurality of tuftingblades 14 in respective fixed positions relative to the blade block 12along the first axis 16. The fastener(s) 26 can comprise, for example,one or more screws (e.g., four set screws, as shown). In yet furtheraspects, the fastener(s) 26 can comprise a clamp, one or more lockingpins, a latch, combinations thereof, and the like. The fastener(s) 26can be loosened to allow the tufting blades 14 to slide along the firstaxis 16 for repositioning the tufting blades relative to the blade block12 or removal from the blade block. The fastener(s) 26 can then betightened to fix the blades axially relative to the blade block 12 alongthe first axis 16. The blade block 12 can be configured for mounting toa tufting machine for use. As is known, in use, tufting blades aremounted to the tufting machine as blade assemblies 10.

A grinder 28 can be configured to grind the tufting blades 14 with thetufting blades received within the blade block 12. A fixture 30 can beconfigured to hold one or more blade assemblies as the grinder 28 grindsthe tufting blades. In exemplary aspects, the fixture 30 can hold asingle blade block. In other aspects, the fixture can hold two, three,four, five, six, or more blade blocks. The fixture 30 can hold the bladeassemblies 10 in a particular orientation relative to a grinding element(e.g., a grinding wheel 29) of the grinder 28 in order to form aparticular profile, such as, for example, a predetermined cutting angleand, optionally, a predetermined relief angle at the blade edge 22.

In exemplary aspects, the grinder 28 can comprise a grinding wheel 29that is configured to rotate about a rotational axis. The grinder 28 canfurther comprise a plurality of actuators (e.g., linear actuators) thatare configured to control the position of the grinding wheel 29 along x,y, and z axes (e.g., first and second perpendicular horizontal axes anda vertical axis) and an actuator (e.g., a motor) for impartingrotational movement of the grinding wheel. For example, the grinder 28can be a computer numerical control (CNC) grinder that can haveprogrammable control of rotation speed, position and linear movementspeed of the grinding wheel. In various exemplary aspects, the grindercan be a 5-axis CNC grinder. In exemplary aspects, the grinder 28 can bea commercially available CNC grinder, such as a WELDON CNC grinderprovided by Weldon Solutions of York, PA.

Blade Alignment for Grinding

Referring to FIGS. 3A-4 , a first blade alignment assembly 40 can beconfigured to position each tufting blade 14 of the plurality of tuftingblades relative to the blade block 12 along the first axis 16 in agrinding configuration prior to grinding. For example, it iscontemplated that the blades can advantageously be ground with the bladeedges 22 positioned close to the blade block (e.g., no more than 30 mm,no more than 20 mm, no more than 15 mm, or no more than 10 mm from theblade block). Further, the blade edges 22 can be axially staggeredrelative to each other along the third axis 20, extending differentdistances from the blade block along the first axis 16. For example, afirst blade 12 a at a first end 13 of the blade assembly 10 along thethird axis 20 can extend from the blade block by a first distance, andeach sequential blade along the third axis 20 can be incrementallyspaced by a greater distance (e.g., optionally, by the same increment)than the first distance. It is contemplated that this spacing can, inconjunction with an angle at which the blade block is held relative tothe grinding element, form a predetermined blade angle. As shown in FIG.3A, the predetermined blade angle can correspond to θ1, an angle thatthe top edges of the blades make relative to the third axis 20 of theblade block. The predetermined blade angle can be, for example, fromabout 15 to about 60 degrees, or from about 20 to about 45 degrees, orabout 22 degrees.

Referring to FIGS. 4 and 12 , the first blade alignment assembly 40 cancomprise a first linear actuator 42 that is coupled to a first guide 44.In some optional aspects, the first blade alignment assembly 40 canfurther comprise a second linear actuator 46 that is coupled to a secondguide 48. The first actuator 42 can be configured to move the firstguide 44 in a first direction to shift the blade edges 22 of the tuftingblades 14 outwardly from the blade block 12 along the first axis 16. Thesecond actuator 46 can then move the second guide 48 against the tuftingblades 14 to position the tufting blades 14 in their proper grindingconfiguration (FIG. 1 ), with each tufting blade positioned at itsrespective position extending the predetermined distance from the bladeblock 12 along the first axis. The second guide 48 can define a surface50 (e.g., a planar profile or a stepped profile) that defines the spacedrelationship between the blade block 12 and each of the tufting bladesalong the first axis 16 (e.g., the incremental distances between thetufting blades). Optionally, the first actuator 42 and first guide 44can be omitted.

The system can comprise a device for disengaging the fastener(s) 26 topermit movement of the tufting blades relative to the blade block andfor manipulating the fastener(s) to secure (e.g., retain) the pluralityof tufting blades relative to the blade block. For example, a driver 52(e.g., a torque screwdriver) can loosen the fastener(s) prior toengagement of the first blade alignment assembly 40 to enable movementof the tufting blades 14 relative to the blade block 12. The driver 52can then tighten the fastener(s) after the first blade alignmentassembly 40 positions the tufting blades 14 for grinding. The driver 52can torque the fasteners to a predetermined torque. The device fordisengaging and engaging the fastener(s) 26 can be configured for theparticular type of fastener. Thus, for example, for a fastenercomprising a locking clamp, the device for disengaging and engaging thefastener(s) 26 can comprise an arm that actuates (e.g., effects movementof) the locking clamp about and between a disengaged condition and anengaged condition.

Receipt and Pre-Grinding Processing of Blade Assemblies

The system 100 can receive a plurality of blade assemblies 10 positionedwithin a tray 54. The tray 54 can define one or more receptacles thatmaintain the plurality of blade assemblies 10 in a predeterminedorientation and spaced relationship relative to each other. The tray 54can comprise an identifier that is associated with at least oneparameter of the plurality of blade assemblies therein. That is, theidentifier can indicate what blade assemblies 10 are placed therein. Forexample, different blade assemblies 10 can be configured for differentmachines or otherwise associated with particular inventories (e.g.,particular plants or locations within a plant). Thus, it can beadvantageous to identify the blade assemblies 10 within the tray 54.Optionally, the identifier can be a color. For example, the tray, or aportion of the tray (e.g., a stripe 55) can have a color associated witha particular grouping of blade assemblies (e.g., blade assembliesconfigured for a particular tufting machine). In some aspects, theidentifier can comprise a symbol or an alphanumeric identification or acombination thereof. In further aspects, the identifier can be amachine-readable identifier, such as, for example, an optical orelectronically readable identifier, such as, for example, a barcode, aQR code, a scannable tag, a recognizable image, combinations thereof,and the like.

Referring to FIGS. 6, 13A, and 13B, the system 100 can comprise a firstconveyor 60 that is configured to receive a plurality of blade assembles10 in a tray 54. The first conveyor 60 can be, for example, a belt orroller conveyor. The system 100 can further comprise a second conveyor62 that is configured to move the blade assembles 10 about and betweenone or more processing stations. For example, the second conveyor 62 cancomprise a transfer pallet 70 that is configured to hold a plurality of(e.g., four) blade assemblies 10. Optionally, the trays 54 can bestacked. For example, the trays can be stacked in a plurality of layers(e.g., six layers high) on the first conveyor 60.

The system 100 can comprise a first end of arm tool 64 that isconfigured to receive the blade assemblies 10 from the first conveyor 60(e.g., from the tray 54) and transfer the blade assemblies to the secondconveyor 62. The end of arm tool 64 can be coupled to a robotic arm 65,such as, for example, a six- or seven-axis robotic arm. The end of armtool 64 can comprise a suction gripper, a clamp, or any suitable toolfor lifting and releasing the blade assemblies 10. The first end of armtool 64 can further be configured to grip and move the tray 54. In thisway, the first end of arm tool 64 can move empty trays 54 to allow forsubsequent trays 54 to advance for unloading.

Optionally, the first end of arm tool 64 can position each bladeassembly 10 at a visual inspection assembly 66. The visual inspectionassembly 66 can comprise an optical sensor or scanner (e.g., a camera, alaser scanner, or other machine vision system) that can detect one ormore attributes of the blade assembly 10. The one or more attributes cancomprise, for example, number of blades, a shortest blade length, aroughness of blades, or a combination thereof. The optical sensor orscanner can be in communication with one or more processors to analyzedata from the optical sensor or scanner. The processor(s) can optionallybe part of the visual inspection assembly 66 or in electricalcommunication therewith. The processor(s) can be in communication withmemory for performing routines to analyze the attributes of the bladeassembly 10. In exemplary aspects, the processor(s) and memory can beembodied as the processor 1003 and mass storage device 1004 of thecomputing device 1001 as further described herein with reference to FIG.15 . For example, the processor 1003 can be configured to determine ifthe blade assembly 10 has the correct number of tufting blades 14 (or ifany of the blades are broken). The processor 1003 can further beconfigured to determine whether all of the blades have a sufficientlength for grinding and reuse. For example, the processor can determine,based on the optical sensor or scanner (e.g., camera) the length of eachof the blades, and the processor can further compare the length of eachof the blades (or the shortest blade) to a minimum threshold. If theprocessor 1003 determines that blade assembly 10 has all necessarytufting blades 14 and the blades are of sufficient length for grindingand reuse, the blade assembly 10 can be moved to the transfer pallet 70of the second conveyor 62. The visual inspection assembly 66 can furtherbe configured to determine blade thickness and the hand/orientation(e.g., left-handed or right-handed) of blades in the block.

If the blade assembly 10 does not have enough tufting blades 14, or ifthe blades are too short for grinding and reuse, the blade assembly 10can be moved to a rejection station. The rejection station can be areceptacle (e.g., a tray, bucket, etc.) that can receive rejected bladeassemblies 10. Optionally, the end of arm tool 64 can replace therejected blade assembly with a makeup blade assembly from a makeupassembly supply. For example, the end of arm tool 64 can move the makeupblade assembly from the makeup assembly supply to the transfer pallet 70of the second conveyor 62.

In some aspects, the rejection station can comprise a reloading station.In some optional aspects, the reloading station can be operatedmanually. For example, an operator can remove any blades that are tooshort or otherwise unusable and add blades to replace removed or omittedblades. In other aspects, an automated station can be configured todetermine, based, for example, on data from the visual inspectionassembly 66, which blades are missing and/or need to be replaced, andthe reloading station can comprise a supply of usable (e.g., new)blades, an end of arm tool for removing spent blades and positioning theusable blades within the blade block. The reloading station can furthercomprise a driver for loosening the fastener(s) 26 for release of thespent blades and tightening the fastener for securing the blades withinthe blade block.

In some aspects, the visual inspection assembly 66, via the processor1003, can further be configured to classify the roughness of the bladeassembly based on the roughest tufting blade of the plurality of tuftingblades in order to determine the necessary amount of grinding to providerefurbished, even blades. For example, the visual inspection assembly 66can be configured to classify the blades as “mild wear,” “moderatewear,” or “severe wear.” The classification can be associated with theworst blade of the plurality of blades (i.e., the blade requiring themost grinding to be in refurbished condition) and can correspond to orcorrelate with a length of blade needed to be ground from the worsttufting blade to put said tufting blade in refurbished condition (e.g.,with a straight edge 22). A predetermined length can be removed fromeach blade during grinding based on the classification. Lesser amountsof wear can be associated with lesser amounts of grinding, and largeramounts of wear can be associated with relatively more grinding. Thus,the amount of grinding can be proportional to the wear of the blades.For example, mild wear can be associated with one millimeter of bladegrinding (across all blades), moderate wear can be associated with twomillimeters of blade grinding, and severe wear can be associated withthree millimeters of blade grinding. Other amounts of blade grinding canbe selected for each category depending on user specifications.Similarly, it is contemplated that more or less than the statedclassifications of wear can be employed within the system as desired.For example, it is contemplated that the system can be configured toclassify the blades as “low wear” or “high wear.”

In some optional aspects, roughness can be quantified as a maximumvariation in the edge of the blade surface along the first axis 16, whenmoving along the edge of the blade surface across the second axis 1 8.For example, chips in the blade can cause wear or chips or wear thatlead to variation of the edge of the blade surface across the secondaxis 18. The variation can be measured as a distance (e.g., measured inmillimeters) along the axis 16. The measured distance of variation canbe compared to one or more thresholds in order to classify the wear ofthe blades. For example, using the example above, the threshold betweenmild and moderate wear can be 1 millimeter. Thus, moving across theblade surface a measured variation of less than 1 millimeter along thefirst axis 16 can be classified as mild wear; measured variation ofgreater than 1 millimeter along the first axis 16 but less than 2millimeters can be classified as moderate wear; and a variation ofgreater than 2 millimeter along the first axis 16 can be classified assevere wear. Variations higher than a maximum threshold (e.g., greaterthan severe wear) can lead to the blade being rejected.

The second conveyor 62 can transfer the blade assemblies 10 to the firstblade alignment assembly 40. In some aspects, the first blade alignmentassembly 40 can sequentially adjust the position of the blades of eachblade assembly 10 in the pallet 70.

Moving the Blade Assemblies to and From Grinders

Referring to FIGS. 9-10F, a second end of arm tool 72 can be configuredto position and secure the blade assemblies 10 on the fixture 30. Thesecond end of arm tool 72 can further be configured to move the bladesabout and between one or more (e.g., three) grinders 28. For example,the second end of arm tool 72 can be coupled to a robotic arm 74 that ismovable along a rail 76. The rail 76 can extend between the secondconveyor 62 and one or more (e.g., three) grinders 28.

At a loading/unloading station 78, the second end of arm tool 72 can beconfigured to pick up each blade assembly 10 and place the bladeassembly 10 in a fixture 30. The fixtures 30 can be held by a fixturemount 79. In some aspects, the end of arm tool 72 can load two fixtures30, each holding a plurality of (e.g., four) blade assemblies 10. Thesecond end of arm tool 72 can: (a) simultaneously grip the two loadedfixtures 30, (b) move to a grinder 28 while simultaneously gripping thetwo loaded fixtures, (c) pick up, from the grinder 28, two additionalfixtures 30′ (with ground blade assemblies 10′ thereon), (d) replace thepicked up additional fixtures with the fixtures 30 holding un-groundblade assemblies, and (e) move the two additional fixtures 30′ to theunloading station 79, where the end of arm tool 72 can unload the groundblade assemblies 10′ on the pallet 70 of the second conveyor 62.

The second end of arm tool 72 can comprise a first gripper 82 that isconfigured to grip individual blade assemblies 10. The second end of armtool 72 can further comprise one or more (e.g., four) grippers 84 thatare configured to grip respective fixtures 30. The grippers 84 can bearranged with half of the grippers 84 (e.g., two grippers 84) on a firstside 86 and half of the grippers 84 on the opposed side 87. The secondend of arm tool 72 can be configured to rotate about a rotational axis88 to selectively position the grippers 84 a or the grippers 84 b at theloading mounts 89 of the grinders 28. In this way, as further disclosedherein, the second end of arm tool 72 can rotate to swap, in a grinder,a fixture 30 holding ground blade assemblies 10′ with a fixture 30holding unground blade assemblies 10.

FIGS. 10A-10E illustrate use of the second end of arm tool 72 forloading the blade assemblies 10 in the fixture, moving the figures forgrinding, and returning the blade assemblies to the second conveyor 72.Referring to FIG. 10A, the second end of arm tool 72 can load bladeassemblies 10 from the pallet 70 of the conveyor 62 in the fixtures 30with the first gripper 82. The fixtures 30 can be held in loading mounts89. Referring to FIG. 10B, the second end of arm tool 72 can grip thefixtures 30 with the grippers 84 to remove the fixtures from the loadingmounts 89. Referring to FIG. 10C, the second end of arm tool 72 can movealong the rail 76 to a grinder 80. Referring to FIG. 10D, the grippers84 of the second end of arm tool 72 can grip the fixtures 30′ and removethe fixtures 30′ from fixture mounts 90. Referring to FIG. 10E, thesecond end of arm tool can rotate about the rotational axis 88 and placethe fixtures 30 (with un-ground blade assemblies 10) in the fixturemounts 90. The second end of arm tool 72 can then return to the loadingmounts 89. The second end of arm tool can then use the first gripper 82to load the ground blade assemblies 10′ in the pallet 70 of the secondconveyor 62 for further processing.

Referring to FIG. 10A, in exemplary aspects, the second end of arm tool72 can be configured to replace a first fixture 30 a with a secondfixture 30 b from a fixture storage bank 31. It is contemplated that thefixtures can be configured for a particular type of blade assembly 10.Thus, the system 100 can be adapted for use with multiple differentkinds of blade assemblies 10.

Grinding the Blade Assemblies

Referring to FIGS. 2, 3A, and 3B, with the blade assemblies 10 heldwithin the fixture 30 in the grinder 28, the grinding wheel 29 can beconfigured to pass across the blades 14 along a grinding wheel movementaxis 92. In some aspects, the grinding wheel movement axis 92 can beparallel to the third axis 20 or within 30 degrees, within 20 degrees,or within 10 degrees of parallel to the third axis 20. This can contrastwith conventional grinding, in which the grinding wheel moves along thethickness of the blade (with the blade removed from the blade block).

As shown in FIG. 3A, which is a schematic diagram of a blade assembly 10and grinding wheel 29 looking along the grinding wheel movement axis,the blades 14 can be held by the fixture 30 (FIG. 2 ) so that the loweredge of the grinding wheel, moved along the grinding wheel movement axis92 (into the page in FIG. 3A and shown in FIG. 3B), form a plane 94. Theplane 94 can be offset from perpendicular to the first axis 16 by anangle θ1. Thus, the grinding wheel can leave a blade edge having a bladeangle equal to the angle θ1. Because the blades are staggered relativeto each other, the first longitudinal ends 24 of the blades cansimultaneously positioned along a plane, wherein said plane forms thedesired blade angle relative to the first axis 16, and the grinder canpass along said plane, thereby forming the blade angle on each of theblades. Thus, the staggering of the blades relative to each other canenable all of the blades to be sharpened simultaneously.

As shown in FIG. 3B, which is a schematic diagram of a blade assembly 10 and grinding wheel 29 looking perpendicular to the grinding wheelmovement axis 92, the blade assembly 10 can be held by the fixture withthe first axis 16 at an angle offset from perpendicular to the grindingwheel movement axis 92 by an angle θ2. In this way, the grinding wheelcan form a relief angle on the blades 14 equal to the angle θ2.

Post-Grinding Processing of Blade Assemblies

Once returned from the grinder 28 to the pallet 70, the (sharpened)ground blade assemblies 10′ can receive one or more post-grindingprocessing procedures, as described further herein. It is contemplatedthat one or more of the post-grinding processing procedures can beomitted, other post-grinding processing procedures can be added, and theorder of the post-grinding processing procedures can be rearranged as isdesirable.

Referring to FIGS. 5-6 , in some aspects, the ground blade assemblies10′ can be chamfered. For example, a chamfering station 110 can comprisea chamfer grinder. The chamfer grinder can be configured to form achamfer 25 on the each blade 14 of each blade assembly 10 in the pallet70. The chamfer 25 can be formed at the portion of the blade furthestfrom the blade block (e.g., the tallest portion of the blade along therelief angle). The chamfer grinder can be, for example, a grinding wheelthat is configured to pass across the blades to form said chamfer.

The ground blade assemblies 10′ can be deburred at a deburring station120 (see also FIG. 13E). For example, the deburring station 120 cancomprise a wire brush that is configured to pass across the blade edge22 of each blade 14 of each blade assembly 10 in the pallet 70. Infurther aspects, a nylon brush with abrasives embedded therein or adevice that blasts abrasive media across the ground blade assemblies 10′can be used to deburr the blade assemblies.

The ground blade assemblies 10′ can be adjusted to reposition the bladesrelative to the blade block along the first axis 16. The blades can bepositioned relative to the blade block in use positions, as shown inFIG. 5 . In some aspects, the blades can be repositioned by a secondblade alignment assembly 130 that is configured similarly to that of thefirst blade alignment assembly.

In exemplary aspects and with reference to FIG. 11 , the second bladealignment assembly 130 can comprise a first linear actuator 132 that iscoupled to a first guide 134. In some optional aspects, the second bladealignment assembly 130 can further comprise a second linear actuator 136that is coupled to a second guide 138. The first actuator 132 can beconfigured to move the first guide 134 in a first direction to shift theblade edges 22 of the tufting blades 14 outwardly from the blade block12 along the first axis 16. The second actuator 136 can then move thesecond guide 138 against the tufting blades 14 to position the tuftingblades 14 in their proper grinding configuration, with each tuftingblade positioned at its respective position extending the predetermineddistance from the blade block 12 along the first axis. The second guide138 can define a surface 140 (e.g., a planar profile) that defines thespaced relationship between the blade block 12 and each of the tuftingblades along the first axis 16 (e.g., the incremental distances betweenthe tufting blades).

A driver 142 (e.g., a torque screwdriver) can loosen the fastener(s)prior to engagement of the second blade alignment assembly 130 to enablemovement of the tufting blades 14 relative to the blade block 12. Thedriver 142 can then tighten the fastener(s) after the second bladealignment assembly 130 positions the tufting blades 14 for grinding. Thedriver 142 can torque the fasteners to a predetermined torque.

Referring to FIG. 13B, in some aspects, the ground blade assemblies 10′can receive or otherwise be associated with printed information relevantto the blade assembly (e.g., an identifying tag). Such printedinformation can include a time and date of grinding, a batch number,grinder number or other grinder identifier associated with a particulargrinder that performs the grinder, or an associated plant. For example,in some aspects, each blade assembly can receive, printed thereon, atime, a date, a plant, and a batch number. A marking station 170 can beconfigured to print the printed information. The marking station 170 cancomprise, for example, a printer, such as an inkjet printer 172. Infurther aspects, the marking station 170 can comprise previously printedinformation stored on labels that can be adhered to the blade assembly10′.

Before marking, previous markings can be removed by, for example, a wirebrush 162 at a cleaning station 160 (see also FIG. 13D). In exemplaryaspects, the first end of arm tool 64 can position the blade assembly atthe wire brush 162 for removing previously printed information. Thefirst end of arm tool 64 can then hold the blade assembly 10′ at theinkjet printer 172 for printing of the printed information. In furtheraspects, the printed information can be applied to the blade assembly10′ via an adhesive label. In yet further aspects, a laser can etchidentifying information (a time, a date, a plant, and/ or a batchnumber) in to the blade assembly.

The visual inspection assembly 66 (or another visual inspectionassembly) can then be used to inspect the ground blade assembly 10′. Thevisual inspection assembly 66 can be configured (in conjunction with theprocessor 1003) to inspect the printed data. In further aspects, thevisual inspection assembly 66 can be configured to determine if theblade assembly 10 passes or fails at least one visual inspection metric.For example, the visual inspection metrics can comprise one or more of:whether all of the blades are present, whether the blades are properlypositioned relative to the blade block, whether the blades are bent, orwhether the blades have any irregular edges. If the blade assembly 10fails, the blade assembly can be deposited in the rejection station.

In an exemplary workflow of the first end of arm tool 64, the first endof arm tool 64 can pick up an unground blade assembly 10, present theunground blade assembly at the first inspection assembly, (if notrejected) place the unground blade assembly on the pallet 70 of thesecond conveyor 62, and then pick up a ground blade assembly 10′, movethe ground blade assembly to the wire brush 162, move the ground bladeassembly to the marking station 170, move the ground blade assembly tothe visual inspection assembly 66, and then place the ground bladeassembly in a tray on a third conveyor 63. The third conveyor 63 can beconfigured to receive and transport ground blade assemblies 10′ withintrays. In other aspects, and with reference to FIG. 13F, a third roboticarm 190 comprising an end of arm tool can handle the ground bladeassemblies 10′. For example, in some aspects, the third robotic arm 190can pick up a ground blade assembly 10′. In some aspects, the thirdrobotic arm 19 can move the ground blade assembly to the cleaningstation 160 (e.g., for cleaning via the wire brush 162 (FIG. 13D). Insome aspects, the third robotic arm 19 can move the ground bladeassembly to the marking station 170. In some aspects, the third roboticarm 19 can move the ground blade assembly to the visual inspectionassembly 66. In some aspects, the end of arm tool 62 or the thirdrobotic arm 190 can present the ground blade assembly 10′ in one or morepositions at the visual inspection assembly 66 for visual inspection.

Referring to FIG. 6 , in exemplary aspects, the system 100 can comprisean infeed station A, a loading station B, a visual inspection station C,an initial driver station D, an initial positioning station E, a fixtureloading/unloading station F, a fixture storage station G, a chamferingstation H, a deburring station I, a final driver station J, a finalrepositioning station K, a cleaning station L, an printing station M, adisposition area N, a tray filling station O for receiving ground bladeassemblies, a tray collection station P, a makeup area Q, and anoffloading station R. The infeed station can comprise or be defined bythe first conveyor 60. The loading station B can be defined in part bythe second conveyor 62 where the first end of arm tool 64 positionsblade assemblies. The visual inspection station C can comprise or bedefined by the visual inspection assembly 66. The initial driver stationD can comprise the first driver 52. The initial positioning station Ecan comprise the first blade alignment assembly 40. The figure storagestation G can comprise the fixture storage bank 31 and can holddifferent fixtures (e.g., fixtures 30 a,b) for interchanging based onwhich blade assemblies are being ground. The chamfering station H can beembodied by the chamfering station 110 as disclosed herein. Thedeburring station I can be embodied by the deburring station 120 asdisclosed herein. The final driver station J can comprise the seconddriver 142. The final repositioning station K can comprise the secondblade alignment assembly 130. The cleaning station L can be embodied bythe cleaning station 160. The printing station M can be embodied by theprinting station 170. The disposition area N can define the rejectionstation as disclosed herein. The tray filling station O for receivingground blade assemblies can comprise the third conveyor 63. The traycollection station P can receive empty trays 54. The makeup area Q canhold replacement blade assemblies for to replace blade assemblies thatthe visual inspection assembly 66 determines to be rejected. Theoffloading station R can comprise the third conveyor 63.

In exemplary aspects, the blade assemblies can be received at the infeedstation A. The first conveyor 60 can receive the blade assemblies withina tray 54. The first end of arm tool 64 can present each blade assemblyat the vision inspection station C. If the blade assembly passes, thefirst end of arm tool 64 can transfer the blade assembly to the loadingstation B. If the blade assembly is rejected, the first end of arm tool64 can place the rejected blade assembly in the disposition area N anddraw a replacement blade assembly from the makeup area Q, placing thereplacement blade assembly at the loading station B. The second conveyor62 can move each of the blade assemblies in a pallet 70 to the initialdriver station D in position with the first driver 52 for loosening. Thesecond conveyor 62 can then move each of the blade assemblies in thepallet to the initial reposition station E, aligning each of the bladeassemblies with the first blade alignment assembly 40 for loosening thefasteners 26 to free the blades. The second conveyor 62 can then moveback to the initial driver station D for tightening of the bladeassemblies for tightening the fasteners 26 for fixing the blades.

The second conveyor 62 can then move the blade assemblies to the fixtureloading/unloading station F, where the second end of arm tool 72 canplace the blade assemblies in a fixture, after selecting the properfixture from the fixture storage station G. After grinding, second endof arm tool 72 can return the blade assemblies to the second conveyor62. The second conveyor can move the blade assemblies to the chamferstation H and then to the deburring station I. The second conveyor 62can then move the blade assemblies between the final driver station Jand final repositioning station K in order to loosen the fasteners tofree the blades, align the blades, and then tighten the fasteners to fixthe blades, as further described herein. The second conveyor can thenmove the blade assemblies for accessing of the first end of arm tool 64.The first end of arm tool can present the blade assemblies to thecleaning station L, printing station M, visual inspection station C, andthen place the blade assemblies in the tray filling station O. The thirdconveyor 63 can then move a tray filled with blade assemblies to theoffloading station R.

Computing Device

Except as where otherwise indicated, it is contemplated that any of themethod steps described herein can be performed using one or moreprocessors of one or more computing devices. FIG. 15 shows a controlsystem 1000 including an exemplary configuration of a computing device1001 for use with the system 100. In some aspects, the computing device1001 can be a single computing device that controls all aspects of thesystem 100. In other aspects, the computing device 1001 can be embodiedby a plurality of computing devices that are in communication with eachother on a network. For example, the computing device 1001 can comprise,or be embodied as, a tablet, smartphone, laptop, or desktop computer. Infurther aspects, the computing device can be embodied as a programmablelogic controller (PLC). In yet further aspects, various components(e.g., the first, second, and third conveyors, first and second end ofarm tools, alignment assemblies, visual inspection assembly, drivers,printers, etc. can comprise respective controllers or computing devicesthat communicate with the computing device 1001/PLC to perform variousfunctions associated with the computing device 1001.

The computing device 1001 may comprise one or more processors 1003, asystem memory 1012, and a bus 1013 that couples various components ofthe computing device 1001 including the one or more processors 1003 tothe system memory 1012. In the case of multiple processors 1003, thecomputing device 1001 may utilize parallel computing.

The bus 1013 may comprise one or more of several possible types of busstructures, such as a memory bus, memory controller, a peripheral bus,an accelerated graphics port, and a processor or local bus using any ofa variety of bus architectures.

The computing device 1001 may operate on and/or comprise a variety ofcomputer readable media (e.g., non-transitory). Computer readable mediamay be any available media that is accessible by the computing device1001 and comprises, non-transitory, volatile and/or non-volatile media,removable and non-removable media. The system memory 1012 has computerreadable media in the form of volatile memory, such as random accessmemory (RAM), and/or non-volatile memory, such as read only memory(ROM). The system memory 1012 may store data such as position data 1007and/or program modules such as operating system 1005 and movementcontrol software 1006 that are accessible to and/or are operated on bythe one or more processors 1003.

The computing device 1001 may also comprise otherremovable/non-removable, volatile/non-volatile computer storage media.The mass storage device 1004 may provide non-volatile storage ofcomputer code, computer readable instructions, data structures, programmodules, and other data for the computing device 1001. The mass storagedevice 1004 may be a hard disk, a removable magnetic disk, a removableoptical disk, magnetic cassettes or other magnetic storage devices,flash memory cards, CD-ROM, digital versatile disks (DVD) or otheroptical storage, random access memories (RAM), read only memories (ROM),electrically erasable programmable read-only memory (EEPROM), and thelike.

Any number of program modules may be stored on the mass storage device1004. An operating system 1005 and movement control software 1006 may bestored on the mass storage device 1004. One or more of the operatingsystem 1005 and movement control software 1006 (or some combinationthereof) may comprise program modules and the movement control software1006. The position data 1007 may also be stored on the mass storagedevice 1004. The position data 1007 may be stored in any of one or moredatabases known in the art. The databases may be centralized ordistributed across multiple locations within the network 1015.

A user may enter commands and information into the computing device 1001using an input device (not shown). Such input devices comprise, but arenot limited to, a joystick, a touchscreen display, a keyboard, apointing device (e.g., a computer mouse, remote control), a microphone,a scanner, tactile input devices such as gloves, and other bodycoverings, motion sensor, speech recognition, and the like. These andother input devices may be connected to the one or more processors 1003using a human machine interface 1002 that is coupled to the bus 1013,but may be connected by other interface and bus structures, such as aparallel port, game port, an IEEE 1394 Port (also known as a Firewireport), a serial port, network adapter 1008, and/or a universal serialbus (USB).

A display device 1011 may also be connected to the bus 1013 using aninterface, such as a display adapter 1009. It is contemplated that thecomputing device 1001 may have more than one display adapter 1009 andthe computing device 1001 may have more than one display device 1011. Adisplay device 1011 may be a monitor, an LCD (Liquid Crystal Display),light emitting diode (LED) display, television, smart lens, smart glass,and/ or a projector. In addition to the display device 1011, otheroutput peripheral devices may comprise components such as speakers (notshown) and a printer (not shown) which may be connected to the computingdevice 1001 using Input/Output Interface 1010. Any step and/or result ofthe methods may be output (or caused to be output) in any form to anoutput device. Such output may be any form of visual representation,including, but not limited to, textual, graphical, animation, audio,tactile, and the like. The display 1011 and computing device 1001 may bepart of one device, or separate devices. The display 1011 can show oneor more outputs indicative of system progress, for example.

The computing device 1001 may operate in a networked environment usinglogical connections to one or more remote computing devices 1014 a,b,c.A remote computing device 1014 a,b,c may be a personal computer,computing station (e.g., workstation), portable computer (e.g., laptop,mobile phone, tablet device), smart device (e.g., smartphone, smartwatch, activity tracker, smart apparel, smart accessory), securityand/or monitoring device, a server, a router, a network computer, a peerdevice, edge device or other common network node, and so on. Logicalconnections between the computing device 1001 and a remote computingdevice 1014 a,b,c may be made using a network 1015, such as a local areanetwork (LAN) and/or a general wide area network (WAN), or a Cloud-basednetwork. Such network connections may be through a network adapter 1008.A network adapter 1008 may be implemented in both wired and wirelessenvironments. Such networking environments are conventional andcommonplace in dwellings, offices, enterprise-wide computer networks,intranets, and the Internet. It is contemplated that the remotecomputing devices 1014 a,b,c can optionally have some or all of thecomponents disclosed as being part of computing device 1001. In variousfurther aspects, it is contemplated that some or all aspects of dataprocessing described herein can be performed via cloud computing on oneor more servers or other remote computing devices. Accordingly, at leasta portion of the control system 1000 can be configured with internetconnectivity.

FIG. 14 schematically illustrates the control system 1000. For example,the computing device 1001 (PLC) can be in communication with the plantnetwork and can be in communication with: valve banks 202, operatorinterfaces 1060, first end of arm tool 64, the visual inspection system66, the drivers 52, 152, the printer 172, a motion controller 1062 forcontrolling the second conveyor 62, and handheld human machineinterfaces 1064. In exemplary aspects, the valve banks 202 canselectively provide pressurized air to pneumatic devices and/orhydraulics fluid to hydraulic devices. The operator interface 1060 andthe handheld human machine interfaces 1064 can enable operators tocontrol aspects of the system 100. For example, the operator interface1060 and the handheld human machine interfaces 1064 can enable anoperator to start or stop operation, select types of blade assembliesfor processing, change speeds, pause certain routines, etc.

Exemplary Aspects

In view of the described products, systems, and methods and variationsthereof, herein below are described certain more particularly describedaspects of the invention. These particularly recited aspects should nothowever be interpreted to have any limiting effect on any differentclaims containing different or more general teachings described herein,or that the “particular” aspects are somehow limited in some way otherthan the inherent meanings of the language literally used therein.

Aspect 1: A method comprising:

-   grinding a plurality of tufting blades of a blade assembly, wherein    the plurality of tufting blades are received within a blade block    during said grinding,-   wherein the blade assembly has a first axis, a second axis that is    parallel to the first axis, and a third axis that is perpendicular    to each of the first and second axes, wherein each tufting blade of    the plurality of tufting blades has a length that extends along the    first axis, a width that extends along the second axis, and a    thickness that extends along the third axis,-   wherein the plurality of tufting blades are spaced from each other    along the third axis, and-   wherein the blade assembly comprises at least one fastener that is    configured to retain the plurality of tufting blades in respective    fixed positions relative to the blade block.

Aspect 2: The method of aspect 1, further comprising:

-   with the at least one fastener in a disengaged condition that    permits movement of the plurality of tufting blades relative to the    blade block, positioning, using a first guide, each tufting blade of    the plurality of tufting blades relative to the blade block along    the first axis in a grinding configuration; and-   securing, using the at least one fastener, the plurality of tufting    blades relative to the blade block in the grinding configuration.

Aspect 3: The method of aspect 2, further comprising disengaging the atleast one fastener of the blade assembly prior to positioning eachtufting blade of the plurality of tufting blades relative to the bladeblock along the first axis in the grinding configuration.

Aspect 4: The method of aspect 3, wherein the at least one fastenercomprises at least one screw, wherein disengaging the at least onefastener comprises loosening the at least one screw, wherein securing,using the at least one fastener, the plurality of tufting blades in thegrinding configuration comprises tightening the at least one screw.

Aspect 5: The method of any one of aspects 2-4, wherein the first guidecomprises a planar surface.

Aspect 6: The method of any one of aspects 2-5, wherein positioning,using the first guide, each tufting blade of the plurality of tuftingblades relative to the blade block along the first axis comprises:

-   moving, by a first linear actuator, the plurality of tufting blades    along the first axis in a first direction; and-   moving, by the first guide and a second linear actuator that is    coupled to the first guide, the plurality of tufting blades along    the first axis in a second direction that is opposite the first    direction.

Aspect 7: The method of any one of the preceding aspects, whereingrinding the plurality of tufting blades comprises passing a grindingwheel across the tufting blades along a grinding axis that is within 20degrees of parallel to the second axis.

Aspect 8: The method of any one of the preceding aspects, furthercomprising: positioning the blade assembly within a fixture that isconfigured to hold the blade assembly during grinding.

Aspect 9: The method of aspect 8, wherein positioning the blade assemblywithin the fixture comprises positioning a plurality of blade assemblieswithin the fixture, wherein each blade assembly of the plurality ofblade assemblies comprises a plurality of tufting blades received withina respective blade block, and wherein grinding the plurality of tuftingblades comprises grinding the plurality of blade assemblies.

Aspect 10: The method of any one of the preceding aspects, furthercomprising:

-   after grinding the plurality of tufting blades of the blade    assembly, with the at least one fastener in a disengaged condition    that permits movement of the plurality of tufting blades relative to    the blade block, positioning, using a second guide, each tufting    blade of the plurality of tufting blades relative to the blade block    along the first axis in a tufting configuration; and-   securing, using the at least one fastener, the plurality of tufting    blades relative to the blade block in the tufting configuration.

Aspect 11: The method of any one of the preceding aspects, furthercomprising receiving a plurality of blade assemblies positioned within acarrying tray.

Aspect 12: The method of aspect 11, wherein receiving the plurality ofblade assemblies positioned within the carrying tray comprises receivingthe carrying tray on a first conveyor.

Aspect 13: The method of aspect 12, further comprising moving, by thefirst conveyor, the carrying tray to a first end of arm tool.

Aspect 14: The method of aspect 13, further comprising: moving, by thefirst end of arm tool, a first blade assembly of the plurality of bladeassemblies received by the carrying tray to a second conveyor.

Aspect 15: The method of aspect 14, further comprising: visuallyinspecting each tufting blade of the first blade assembly prior togrinding.

Aspect 16: The method of aspect 15, further comprising replacing atleast one tufting blade of the blade assembly that fails inspection witha replacement tufting blade from a replacement tufting blade supply.

Aspect 17: The method of any one of aspects 8-16, further comprising:positioning, by a second end of arm tool, the blade assembly on thefixture.

Aspect 18: The method of any one of aspects 8-17, wherein the fixture isa first fixture, the method further comprising:

replacing the first fixture with a second fixture.

Aspect 19: The method of any one of the preceding aspects, furthercomprising deburring the plurality of tufting blades.

Aspect 20: The method of any one of the preceding aspects, furthercomprising cleaning the plurality of tufting blades.

Aspect 21: The method of any one of the preceding aspects, furthercomprising associating at least one identifying tag with the bladeassembly.

Aspect 22: The method of aspect 21, wherein associating the at least oneidentifying tag with the blade assembly comprises printing at least oneidentifying tag on the blade assembly.

Aspect 23: The method of any one of the preceding aspects, furthercomprising: visually inspecting the blade assembly to determine whetherthe blade assembly passes or fails at least one visual inspectionmetric.

Aspect 24: The method of aspect 23, further comprising: positioning, bya first end of arm tool, the blade assembly in a rejection receptacle ifthe blade assembly fails said at least one visual inspection metric.

Aspect 25: The method of aspect 23, further comprising: positioning, bythe first end of arm tool, the blade assembly in a passing assembly trayif the blade assembly passes said at least one visual inspection metric.

Aspect 26: A system comprising:

-   a blade assembly, the blade assembly comprising a plurality of    tufting blades received within a blade block, wherein the blade    assembly has a first axis, a second axis that is parallel to the    first axis, and a third axis that is perpendicular to each of the    first and second axes, wherein each tufting blade of the plurality    of tufting blades has a length that extends along the first axis, a    width that extends along the second axis, and a thickness that    extends along the third axis, wherein the plurality of tufting    blades are spaced from each other along the third axis, wherein the    blade assembly comprises at least one fastener that is configured to    retain the plurality of tufting blades in respective fixed positions    relative to the blade block;-   a fixture that is configured to hold the blade assembly; and-   a grinder that is configured to grind the tufting blades of the    blade assembly held within the fixture.

Aspect 27: The system of aspect 26, wherein the fixture is configured tohold a plurality of blade assemblies.

Aspect 28: The system of aspect 26 or 27, further comprising:

a first blade alignment assembly that is configured to position eachtufting blade of the plurality of tufting blades relative to the bladeblock along the first axis in a grinding configuration.

Aspect 29: The system of aspect 28, wherein the first blade alignmentassembly comprises a first linear actuator that is configured to movethe plurality of tufting blades along the first axis in a firstdirection; and a second linear actuator coupled to a first guide,wherein the second linear actuator is configure to move the plurality oftufting blades with the first guide along the first axis in a seconddirection that is opposite the first direction.

Aspect 30: The system of aspect 28 or aspect 29, further comprising:

a second blade alignment assembly that is configured to position eachtufting blade of the plurality of tufting blades relative to the bladeblock along the first axis in a tufting configuration.

Aspect 31: The system of aspect 30, wherein the second blade alignmentassembly comprises a first linear actuator that is configured to movethe plurality of tufting blades along the first axis in the firstdirection; and a second linear actuator coupled to a second guide,wherein the second linear actuator is configure to move the plurality oftufting blades with the first guide along the first axis in the seconddirection.

Aspect 32: The system of any one of aspects 26-31, further comprising:

-   a first conveyor that is configured to receive a plurality of blade    assemblies in a carrying tray; and-   a first end of arm tool that is configured to transfer each blade    assembly of the plurality of blade assemblies from the carrying tray    to a second conveyor.

Aspect 33: The system of aspect 32, further comprising the carryingtray, wherein the carrying tray comprises an identifier associated withat least one parameter of the plurality of blade assemblies therein.

Aspect 34: The system of any one of aspects 26-33, further comprising avisual inspection assembly that is configured to inspect each tuftingblade of the blade assembly.

Aspect 35: The system of any one of aspects 26-34, further comprising asecond end of arm tool that is configured to:

-   transfer the blade assembly from the second conveyor to the fixture    for grinding; and-   transfer the blade assembly from the fixture to the second conveyor    after grinding.

Aspect 36: The system of any one of aspects 26-35, further comprising adeburring station.

Aspect 37: The system of any one of aspects 26-36, further comprising acleaning station.

Aspect 38: The system of any one of aspects 26-37, further comprising atagging device that is configured to associate at least one identifyingtag with the blade assembly

Aspect 39: The system of aspect 38, wherein the tagging device is aprinter that is configured to print the at least one identifying tag onthe blade assembly.

Aspect 40: The system of any one of aspects 34-38, wherein the visualinspection assembly is configured to determine whether the bladeassembly passes or fails at least one visual inspection metric.

Although several embodiments of the invention have been disclosed in theforegoing specification, it is understood by those skilled in the artthat many modifications and other embodiments of the invention will cometo mind to which the invention pertains, having the benefit of theteaching presented in the foregoing description and associated drawings.It is thus understood that the invention is not limited to the specificembodiments disclosed herein, and that many modifications and otherembodiments are intended to be included within the scope of the appendedclaims. Moreover, although specific terms are employed herein, as wellas in the claims which follow, they are used only in a generic anddescriptive sense, and not for the purposes of limiting the describedinvention, nor the claims which follow.

What is claimed is:
 1. A method comprising: grinding a plurality of tufting blades of a blade assembly, wherein the plurality of tufting blades are received within a blade block during said grinding, wherein the blade assembly has a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes, wherein each tufting blade of the plurality of tufting blades has a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis, wherein the plurality of tufting blades are spaced from each other along the third axis, and wherein the blade assembly comprises at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block.
 2. The method of claim 1, further comprising: with the at least one fastener in a disengaged condition that permits movement of the plurality of tufting blades relative to the blade block, positioning, using a first guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a grinding configuration; and securing, using the at least one fastener, the plurality of tufting blades relative to the blade block in the grinding configuration.
 3. The method of claim 2, wherein positioning, using the first guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis comprises: moving, by a first linear actuator, the plurality of tufting blades along the first axis in a first direction; and moving, by the first guide and a second linear actuator that is coupled to the first guide, the plurality of tufting blades along the first axis in a second direction that is opposite the first direction.
 4. The method of claim 1, wherein grinding the plurality of tufting blades comprises passing a grinding wheel across the tufting blades along a grinding axis that is within 20 degrees of parallel to the second axis.
 5. The method of claim 1, further comprising: positioning the blade assembly within a fixture that is configured to hold the blade assembly during grinding.
 6. The method of claim 1, further comprising: after grinding the plurality of tufting blades of the blade assembly, with the at least one fastener in a disengaged condition that permits movement of the plurality of tufting blades relative to the blade block, positioning, using a second guide, each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a tufting configuration; and securing, using the at least one fastener, the plurality of tufting blades relative to the blade block in the tufting configuration.
 7. The method of claim 1, further comprising receiving a plurality of blade assemblies positioned within a carrying tray.
 8. The method of claim 7, wherein receiving the plurality of blade assemblies positioned within the carrying tray comprises receiving the carrying tray on a first conveyor.
 9. The method of claim 8, further comprising moving, by the first conveyor, the carrying tray to a first end of arm tool.
 10. The method of claim 9, further comprising: moving, by the first end of arm tool, a first blade assembly of the plurality of blade assemblies received by the carrying tray to a second conveyor.
 11. The method of claim 10, further comprising: visually inspecting each tufting blade of the first blade assembly prior to grinding.
 12. The method of claim 11, further comprising replacing at least one tufting blade of the blade assembly that fails inspection with a replacement tufting blade from a replacement tufting blade supply.
 13. The method of claim 5, further comprising: positioning, by a second end of arm tool, the blade assembly on the fixture.
 14. A system comprising: a blade assembly comprising a plurality of tufting blades received within a blade block, wherein the blade assembly has a first axis, a second axis that is parallel to the first axis, and a third axis that is perpendicular to each of the first and second axes, wherein each tufting blade of the plurality of tufting blades has a length that extends along the first axis, a width that extends along the second axis, and a thickness that extends along the third axis, wherein the plurality of tufting blades are spaced from each other along the third axis, wherein the blade assembly comprises at least one fastener that is configured to retain the plurality of tufting blades in respective fixed positions relative to the blade block; a fixture that is configured to hold the blade assembly; and a grinder that is configured to grind the tufting blades of the blade assembly held within the fixture.
 15. The system of claim 14, further comprising: a first blade alignment assembly that is configured to position each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a grinding configuration.
 16. The system of claim 15, wherein the first blade alignment assembly comprises a first linear actuator that is configured to move the plurality of tufting blades along the first axis in a first direction; and a second linear actuator coupled to a first guide, wherein the second linear actuator is configure to move the plurality of tufting blades with the first guide along the first axis in a second direction that is opposite the first direction.
 17. The system of claim 15, further comprising: a second blade alignment assembly that is configured to position each tufting blade of the plurality of tufting blades relative to the blade block along the first axis in a tufting configuration.
 18. The system of claim 17, wherein the second blade alignment assembly comprises a first linear actuator that is configured to move the plurality of tufting blades along the first axis in the first direction; and a second linear actuator coupled to a second guide, wherein the second linear actuator is configure to move the plurality of tufting blades with the first guide along the first axis in the second direction.
 19. The system of claim 14, further comprising: a first conveyor that is configured to receive a plurality of blade assemblies in a carrying tray; and a first end of arm tool that is configured to transfer each blade assembly of the plurality of blade assemblies from the carrying tray to a second conveyor.
 20. The system of claim 19, further comprising a second end of arm tool that is configured to: transfer the blade assembly from the second conveyor to the fixture for grinding; and transfer the blade assembly from the fixture to the second conveyor after grinding.
 21. The system of claim 14, further comprising a visual inspection assembly that is configured to inspect each tufting blade of the blade assembly.
 22. The system of claim 21, wherein the visual inspection assembly is configured to determine whether the blade assembly passes or fails at least one visual inspection metric. 